U.S. patent application number 12/831492 was filed with the patent office on 2011-01-13 for canister for deposition apparatus, and deposition apparatus and method using the same.
This patent application is currently assigned to Samsung Mobile Display Co., Ltd.. Invention is credited to Won-Bong Baek, Seok-Rak Chang, Bo-Kyung Choi, Yun-Mo Chung, Jong-Won Hong, Min-Jae Jeong, Jae-Wan Jung, Eu-Gene Kang, Dong-Hyun Lee, Ki-Yong Lee, Kil-Won Lee, Ivan Maidanchuk, Heung-Yeol Na, Byoung-Keon Park, Jong-Ryuk Park, Jin-Wook Seo, Byung-Soo So, Tae-Hoon Yang.
Application Number | 20110008540 12/831492 |
Document ID | / |
Family ID | 43427683 |
Filed Date | 2011-01-13 |
United States Patent
Application |
20110008540 |
Kind Code |
A1 |
Na; Heung-Yeol ; et
al. |
January 13, 2011 |
CANISTER FOR DEPOSITION APPARATUS, AND DEPOSITION APPARATUS AND
METHOD USING THE SAME
Abstract
A deposition apparatus, and a canister for the deposition
apparatus capable of maintaining a predetermined amount of source
material contained in a reactive gas supplied to a deposition
chamber when the source material is deposited on a substrate by
atomic layer deposition includes a main body, a source storage
configured to store a source material, a heater disposed outside
the main body, and a first feed controller configured to control
the source material supplied to the main body from the source
storage.
Inventors: |
Na; Heung-Yeol;
(Yongin-city, KR) ; Lee; Ki-Yong; (Yongin-city,
KR) ; Seo; Jin-Wook; (Yongin-city, KR) ;
Jeong; Min-Jae; (Yongin-city, KR) ; Hong;
Jong-Won; (Yongin-city, KR) ; Kang; Eu-Gene;
(Yongin-city, KR) ; Chang; Seok-Rak; (Yongin-city,
KR) ; Yang; Tae-Hoon; (Yongin-city, KR) ;
Chung; Yun-Mo; (Yongin-city, KR) ; So; Byung-Soo;
(Yongin-city, KR) ; Park; Byoung-Keon;
(Yongin-city, KR) ; Maidanchuk; Ivan;
(Yongin-city, KR) ; Lee; Dong-Hyun; (Yongin-city,
KR) ; Lee; Kil-Won; (Yongin-city, KR) ; Baek;
Won-Bong; (Yongin-city, KR) ; Park; Jong-Ryuk;
(Yongin-city, KR) ; Choi; Bo-Kyung; (Yongin-city,
KR) ; Jung; Jae-Wan; (Yongin-city, KR) |
Correspondence
Address: |
STEIN MCEWEN, LLP
1400 EYE STREET, NW, SUITE 300
WASHINGTON
DC
20005
US
|
Assignee: |
Samsung Mobile Display Co.,
Ltd.
Yongin-city
KR
|
Family ID: |
43427683 |
Appl. No.: |
12/831492 |
Filed: |
July 7, 2010 |
Current U.S.
Class: |
427/255.23 ;
118/666; 118/726; 137/334 |
Current CPC
Class: |
Y10T 137/6416 20150401;
C23C 16/45525 20130101; C23C 16/52 20130101; C23C 16/45544
20130101; C23C 16/4481 20130101 |
Class at
Publication: |
427/255.23 ;
118/726; 118/666; 137/334 |
International
Class: |
C23C 16/448 20060101
C23C016/448; C23C 16/52 20060101 C23C016/52; C23C 16/06 20060101
C23C016/06; C23C 16/00 20060101 C23C016/00 |
Foreign Application Data
Date |
Code |
Application Number |
Jul 7, 2009 |
KR |
10-2009-0061715 |
Claims
1. A canister for a deposition apparatus, comprising: a source
storage configured to store a source material; a main body to
receive the source material from the source storage and configured
to supply the source material to the deposition apparatus; a heater
disposed outside the main body to heat the source material received
in the main body; and a first feed controller configured to control
the source material to be supplied to the main body from the source
storage.
2. The canister according to claim 1, wherein the first feed
controller includes a first valve disposed on a first pipe
connecting the main body with the source storage, and a first
controller configured to control the opening or closing of the
first valve.
3. The canister according to claim 2, wherein the first controller
closes the first valve according to an amount of the source
material supplied to the main body through the first pipe.
4. The canister according to claim 1, wherein the source material
includes metal powder.
5. The canister according to claim 1, further comprising: a second
pipe configured to supply a carrier gas to the main body; and a
third pipe configured to exhaust a reactive gas, the reactive gas
being formed by mixing the carrier gas with an evaporated source
gas.
6. A deposition apparatus, comprising: a deposition chamber; a
canister configured to supply a reactive gas to the deposition
chamber; and a carrier gas feeder configured to supply a carrier
gas to the canister, wherein the canister includes a main body
which receives the supplied carrier gas, a heater, a source
storage, and a first feed controller configured to control a source
material supplied from the source storage to the main body.
7. The apparatus according to claim 6, wherein the first feed
controller includes a first valve disposed on a first pipe
connecting the main body with the source storage, and a first
controller configured to control the opening or closing of the
first valve.
8. The apparatus according to claim 7, wherein the first controller
closes the first valve according to an amount of the source
material supplied to the main body through the first pipe.
9. The apparatus according to claim 6, wherein the source material
includes metal powder.
10. The apparatus according to claim 6, further comprising: a
second feed controller configured to control the carrier gas
supplied to the main body from the carrier gas feeder; and a third
feed controller configured to control the reactive gas supplied
from the main body to the deposition chamber.
11. The apparatus according to claim 10, wherein the second feed
controller includes a second valve disposed on a second pipe
connecting the carrier gas feeder with the main body, and a second
controller configured to control the opening or closing of the
second valve, and the third feed controller includes a third valve
disposed on a third pipe connecting the deposition chamber with the
main body and a third controller configured to control the opening
or closing of the third valve.
12. The apparatus according to claim 10, further comprising: a
fourth pipe configured to connect the carrier gas feeder with the
second feed controller and the deposition chamber with the third
feed controller; and a fourth feed controller configured to control
the carrier gas supplied from the carrier gas feeder to the
deposition chamber through the fourth pipe.
13. The apparatus according to claim 12, wherein the fourth feed
controller includes a fourth valve disposed on the fourth pipe, and
a fourth controller configured to control the opening or closing of
the fourth valve.
14. The apparatus according to claim 13, wherein the fourth
controller opens the fourth valve to remove the reactive gas
remaining in the deposition chamber after the deposition is
completed.
15. The apparatus according to claim 6, wherein the deposition
chamber is a chamber for atomic layer deposition (ALD).
16. A deposition method, comprising: opening a first valve
interposed between a main body and a source storage of a canister,
and supplying a predetermined amount of source material to the main
body; closing the first valve after supplying the predetermined
amount of the source material and evaporating the supplied source
material in the main body; supplying a carrier gas to the main body
to be mixed with the evaporated source material; supplying a
reactive gas formed by mixing the carrier gas with the evaporated
source material from the main body to a deposition chamber; and
depositing the source material contained in the reactive gas on a
substrate in the deposition chamber.
17. The method according to claim 16, further comprising, after the
deposition of the source material is completed, opening a fourth
valve interposed in a fourth pipe between the carrier gas feeder
and the deposition chamber to remove the reactive gas remaining in
the deposition chamber through the fourth pipe connecting the
deposition chamber with the main body.
18. The method according to claim 16, wherein the source material
is deposited on the substrate by atomic layer deposition.
19. The method according to claim 16, wherein the source material
includes metal powder.
20. The method according to claim 16, wherein the predetermined
amount of the source material is an amount required for a single
cycle of deposition in the deposition chamber.
21. The canister according to claim 1, wherein the source material
includes a liquid organic material.
22. The apparatus according to claim 6, wherein the source material
includes a liquid organic material.
23. The apparatus according to claim 15, wherein the deposition
chamber includes a support chuck having a temperature controller
configured to maintain a substrate S at a uniform temperature to
perform the ALD.
24. The method according to claim 16, wherein the predetermined
amount of the source material supplied to the main body is in an
amount sufficient to perform a single deposition process.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of Korean Patent
Application No. 10-2009-0061715, filed Jul. 7, 2009 in the Korean
Intellectual Property Office, the disclosure of which is
incorporated herein by reference in.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] An aspect of the present invention relates to a canister for
a deposition apparatus, and a deposition apparatus and method using
the same, and more particularly, to a canister for a deposition
apparatus capable of maintaining an amount of source material
contained in a reactive gas supplied to a deposition chamber during
deposition of the source material on a substrate like atomic layer
deposition, and a deposition apparatus and method using the
same.
[0004] 2. Description of the Related Art
[0005] Since flat panel display devices are lightweight and thin,
the flat panel display devices are used as alternatives to
cathode-ray tube display devices. Examples of the flat panel
display device include liquid crystal display (LCD) devices, and
organic light emitting diode (OLED) display devices. Among these,
the OLED display devices have high brightness and a wide viewing
angle. In addition, since the OLED display devices do not need a
back light, the OLED display devices can be implemented in
ultra-thin structures.
[0006] The OLED display devices are classified into a passive
matrix type and an active matrix type according to a driving
method. The active matrix type OLED display device has a circuit
using a thin film transistor (TFT).
[0007] The thin film transistor generally includes a semiconductor
layer including a source region, a drain region and a channel
region, a gate electrode, a source electrode and a drain electrode.
The semiconductor layer may be formed of polycrystalline silicon
(poly-Si) or amorphous silicon (a-Si). However, since electron
mobility of the poly-Si is higher than that of the a-Si, the
poly-Si is more frequently used.
[0008] One method of crystallizing a-Si into poly-Si is a
crystallization method using a metal, which can crystallize a-Si
into poly-Si in a very short period of time at relatively low
temperature by depositing a metal catalyst on a substrate through
sputtering or atomic layer deposition (ALD), and crystallizing the
a-Si using the metal catalyst as a seed. Here, in the sputtering,
deposition is performed by applying plasma to a metal target. In
the atomic layer deposition, an atomic layer of the metal catalyst
is formed on a substrate through a chemical method using a reactive
gas including the metal catalyst.
[0009] To obtain a uniform crystal, in this crystallization method
using the metal catalyst, a reactive gas has to be supplied to a
deposition chamber with the same amount of metal catalysts as in
every cycle of deposition. However, generally, a canister
configured to supply the reactive gas to the deposition chamber
produces a reactive gas formed by mixing a carrier gas with an
evaporated source material such as the metal catalyst. The
evaporated source material is formed by storing the source material
such as the metal catalyst in a main body and heating the main body
by an external heater in every cycle of deposition. Accordingly,
the amount of the remaining source material in the main body and
the amount of the evaporated source material according to the form
or cross-section of the remaining source are changed, so that the
amount of the source material contained in the reactive gas
supplied to the deposition chamber cannot be uniformly
maintained.
SUMMARY OF THE INVENTION
[0010] Aspects of the present invention provide a canister for a
deposition apparatus capable of maintaining a predetermined amount
of source material contained in a reactive gas supplied to a
deposition chamber from the canister, and a deposition apparatus
and method using the same.
[0011] According to an aspect of the present invention, a canister
for a deposition apparatus includes: a main body; a source storage
configured to store a source material; a heater disposed outside
the main body; and a first feed controller configured to control
the source material supplied to the main body from the source
storage.
[0012] According to another aspect of the present invention, a
deposition apparatus includes: a deposition chamber; a canister
configured to supply a reactive gas to the deposition chamber; and
a carrier gas feeder configured to supply a carrier gas to the
canister. Here, the canister includes a main body, a heater, a
source storage, and a first feed controller configured to control a
source material supplied from the source storage to the main
body.
[0013] According to still another aspect of the present invention,
a deposition method includes: opening a first valve interposed
between a main body and a source storage of a canister, and
supplying a predetermined amount of source material to the main
body; closing the first valve and evaporating the source material;
supplying a carrier gas to the main body to be mixed with the
evaporated source material; supplying a reactive gas formed by
mixing the carrier gas with the evaporated source material to a
deposition chamber; and depositing the source material on a
substrate in the deposition chamber using the reactive gas.
[0014] Additional aspects and/or advantages of the invention will
be set forth in part in the description which follows and, in part,
will be obvious from the description, or may be learned by practice
of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] These and/or other aspects and advantages of the invention
will become apparent and more readily appreciated from the
following description of the embodiments, taken in conjunction with
the accompanying drawings of which:
[0016] FIG. 1 is a schematic diagram of a deposition apparatus
according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0017] Reference will now be made in detail to the present
embodiments of the present invention, examples of which are
illustrated in the accompanying drawings, wherein like reference
numerals refer to the like elements throughout. The embodiments are
described below in order to explain the present invention by
referring to the figures.
[0018] FIG. 1 is a schematic diagram of a deposition apparatus
according to an aspect of the present invention. Referring to FIG.
1, the deposition apparatus includes a deposition chamber 100, a
canister 200 configured to supply a reactive gas to the deposition
chamber 100, and a carrier gas feeder 300 configured to supply a
carrier gas to the canister 200.
[0019] The deposition chamber 100 includes a chamber main body 110,
a shower head 125, a support chuck 115, and an outlet 130. The
shower head 125 is connected with an inlet 120 which injects a
reactive gas into the chamber main body 110 and is configured to
uniformly spray the reactive gas on a substrate S The support chuck
115 is configured to support the substrate S. The outlet 130 is
configured to exhaust the remaining reactive gas. Here, the
deposition chamber 100 may be a chamber for atomic layer deposition
(ALD). In order to facilitate the atomic layer deposition, the
support chuck 115 may further include a temperature controller (not
shown) configured to maintain the substrate S at a uniform
temperature. However, the deposition chamber 100 can be used for
other types of depositions.
[0020] The canister 200 evaporates a source material in every cycle
of deposition and supplies the reactive gas to the deposition
chamber 100. Here, the reactive gas is formed by mixing a carrier
gas supplied from the carrier gas feeder 300 with the evaporated
source material. The canister 200 includes a main body 210
configured to evaporate the source material, a heater 220 disposed
outside the main body 210, a source storage 230 configured to store
the source material, and a first feed controller 240 configured to
control the amount of source material supplied to the main body
210. Here, the source material stored in the source storage 230 may
be metal powder or liquid organic material used in the atomic layer
deposition.
[0021] The first feed controller 240 includes a first valve V1
disposed on a first pipe P1 connecting the main body 210 with the
source storage 230, and a first controller C1 configured to control
opening or closing of the first valve V1. Here, the first
controller C1 controls the opening or closing the first valve V1
according to the amount of source material injected into the main
body 210 through the first pipe P1, and may close the first valve
V1 when the source material required for a first cycle of
deposition in the deposition chamber 100 is supplied to the main
body 210. The first controller C1 can include a sensor to detect
the amount of source material or the sensor can be elsewhere
located.
[0022] In a process of depositing the source material on the
substrate S using the deposition apparatus described with reference
to FIG. 1 according to an embodiment of the present invention, the
first valve V1 of the first pipe P1 interposed between the main
body 210 and the source storage 230 of the canister 200 is open to
supply a predetermined amount of source material to the main body
210. Subsequently, the first valve V1 is closed to prevent the
source material from being supplied to the main body 210, and then
the source material is evaporated by the heater 220 disposed
outside the main body 210. In an embodiment of the present
invention, the source material has been described to be evaporated
after the first valve V1 is closed. Alternatively, the source
material may be evaporated while the source material is being
supplied to the main body 210.
[0023] Afterward being evaporated, the carrier gas is supplied to
the main body 210 through the second pipe P2 interposed between the
main body 210 and the carrier gas feeder 300. Thus, the reactive
gas is formed by mixing the carrier gas with the evaporated source
material within the main body 210. As shown, a second feed
controller 420 configured to control the feed of the carrier gas is
disposed on the second pipe P2 to prevent the carrier gas from
being injected into the main body 210 when the source material is
supplied to the main body 210.
[0024] While not required in all aspects, a third feed controller
430 is disposed at a third pipe P3 connecting the main body 210
with the deposition chamber 100 to prevent the source material from
being evaporated in the main body 210 and the reactive gas from
being supplied in an unstable state to the deposition chamber 100
during the formation of the reactive gas.
[0025] The shown second feed controller 420 includes a second valve
V2 and a second controller C2 configured to control the opening or
closing of the second valve V2. The shown third feed controller 430
includes a third valve V3 and a third controller C3 configured to
control the opening or closing of the third valve V3.
[0026] The third valve V3 is open to supply the reactive gas, which
is formed by mixing the evaporated source material with the carrier
gas in the main body 210, to the deposition chamber 100. The
reactive gas containing the source material is supplied to the
deposition chamber 100 and is uniformly sprayed on the substrate S
through the shower head 125 connected to the inlet 120 of the
deposition chamber 100. The reactive gas containing the source
material that is not deposited on the substrate S is exhausted to
the outside of the deposition chamber 100 through the outlet
130.
[0027] In addition, the deposition apparatus according to a shown
embodiment of the present invention includes a fourth pipe P4
connecting the carrier gas feeder 300 with the second valve V2 and
the deposition chamber 100 with the third valve V3, and a fourth
feed controller 440 disposed on the fourth pipe P4 in order to
remove the reactive gas remaining in the deposition chamber 100 and
the third pipe P3 after deposition. Here, similar to the second and
third feed controllers 420 and 430, the shown fourth feed
controller 440 includes a fourth valve V4 and a fourth controller
C4 configured to control the opening or closing of the fourth valve
V4.
[0028] According to another aspect of the present invention, a
source storage 230 may be included in the canister 200 with a
sufficient amount of source material for a single deposition
process to be supplied to a main body 210 of the canister 200 from
the source storage 230, thereby maintaining an environment of the
canister 200 in which a source material is evaporated in every
cycle of deposition and uniformly maintaining the amount of the
source material contained in a reactive gas supplied by the
canister 200.
[0029] While not required in all aspects, the controllers C1, C2,
C3 and C4 can be implemented using mechanical controllers and/or
using processors.
[0030] Although a few embodiments of the present invention have
been shown and described, it would be appreciated by those skilled
in the art that changes may be made in those embodiments without
departing from the principles and spirit of the invention, the
scope of which is defined in the claims and their equivalents.
* * * * *